2016

Cosmetics Palette
Manufacturing Report

HENRY WALLACE
Henry Wallace 2016

Introduction
The product is a palette which holds a single pressed powder godet. It consists of a
transparent windowed top part, of which the non-windowed sections are foil blocked with a
reflective metallic black finish and opaque black base part which holds the bought-in godet. The
product opens using a rotary hinge which snap-fits together. The aesthetic impression of the palette
is sleek and angular. The palette is a promotional item intended to be given out for free as part of a
marketing campaign.

Parts Reference

Item Part No. Description Material Process Quantity

1 P01 Palette_Base Lotte Starex BC-0130X Injection Moulding 1
ABS
2 G2029 Powder_Godet Bought In Cosmetic 1
(Variable)
3 P02 Palette_Top LG SAN 82TR Injection Moulding 1

Production Quantity
500000 units are to be produced in a 4 week window using multiple injection moulding
machines. The tooling produced will then not be required for future production. As such, a
minimisation of tooling costs is preferable to increased production capacity.

1
Henry Wallace 2016

Calculations for Injection Moulding Sample:

These calculations use the values for the palette base. They are incorporated into the
costings model, but are provided here with explanation. The same equations were used for the
palette top, but with different input data.

Strategy:

As the tooling costs are likely to be the largest cost in this process, the aim is to make one
tool with as few cavities as possible that will allow sufficient units to be made within the production
window. There is no benefit in paying for more advanced tooling to increase production rate beyond
the minimum requirement.

Assumptions:

There are a number of assumptions which have been made in order to predict the
production times and costings of these parts. Significant assumptions are outlined now:

 As the machine size being used is now smaller than the original, the machine rate has been
adjusted to £30 from £42.
 Tooling costs have been estimated from an online calculator at custompartnet.com.
 The process will be using a modular hot runner system already owned by the manufacturer.
 The cost per hour of setting up and taking down the machines is the same as running cost.
This is unlikely from a direct labour cost perspective, but it is being assumed that the
manufacturer factors this in to the machine rate for a run of this length.
 Material Costs have been taken from similar grades of polymer data on zauba.com, a market
tracking website.
 Masterbatch colourant costs taken from Alibaba.com, where it can be readily bought.

Mouldability:

The number of cavities on a tool impacts the time of the whole production run. This depends
on the clamp force of the machine, the required shot weight for the injection unit, and the runner
system being used.

Clamp Force of Machine (tons): 50

Projected Area of Part (cm2): 20.2807

Clamp Force Requirement for ABS (tons/cm2): 0.388

Clamp Force per Cavity (tons) = Projected Area * Clamp Requirement

= 20.2807 * 0.388

= 7.87

Max No. Cavities = Machine Clamp Limit / Clamp Force per Cavity

= 50 / 7.87

= 6.35

The number of cavities used also depends on the weight of polymer being shot at once,
needing to be appropriate for the machine. Using a Gpe 20 Injection Moulding unit:

2
Henry Wallace 2016

Shot Weight PS (g): Min 17, Rec 23, Max 45

Volume of Part (cm3): 4.23759

Density of Lotte Starex BC-0130X ABS (g/cm3): 1.05

Specific Gravity of Lotte Starex BC-0130X ABS: 1.05

To convert Shot Weight from PS to ABS: (Shot Weight PS / 1.05) * Specific Gravity of ABS

As Specific Gravity of ABS = 1.05, this balances

Shot Weight per Cavity (g) = Part Volume * Density of Material

= 4.23759 * 1.05

= 4.45

Total Shot Weight (g) = Shot Weight per Cavity * No. Of Cavities

= 4.45 * 6

= 26.7g

26.7g is within the recommended range of shot weights for the Gpe 20 Injection Moulding
unit being used. From this and the clamp force calculations, it is reasonable to infer that a 6 cavity
mould is possible with this machine. However, the number of machines being used depends on the
cycle time of the process.

Cycle Time = Reset Time + Injection Time + Cooling Time

Injection Time (from mould analysis cad tool) (s) = 9.5

Cooling Time (from mould analysis cad tool) (s) = 8

Reset Time (s) = 1 + (1.75 * Dry Cycle Time) * ((2 * Part Depth + 5) / Stroke Length) ^0.5

Dry Cycle Time (s) = 0.9

Part Depth (cm) = 1

Stroke Length (cm) = 32

Reset Time (s) = 1 + (1.75 * 0.9) * ((2 * 1 + 5) / 32) ^0.5

= 1.7366

Cycle Time (s) = 9.5 + 8 + 1.7366

= 19.24

Quantity Required = 500000

Parts Per Cycle = 6

Time for Production (s) = 19.24 * (500000 / 6)

= 1603334s

3
Henry Wallace 2016

= 18.55 days

After Taking out a day to setup and take down, and building in 5% down time, this is 75% of
the available 28 days for manufacture, which is a reasonable amount of the time being used.
Reducing the number of cavities to 4 requires 113% of the time being used, which would require
another machine and another tool.

Costing:

The cost of the process depends on the time the machines are running, being set up or taken
down, the cost of tooling, and the cost of material used.

Cost of Tooling from online calculator (£) = £43,000

Machine Rate (£/hr) = 30

Time Required (hrs) = Production Time (hrs) + Setup Time (hrs)

= 446 + 48

= 494 hrs

Cost of Machine Time (£) = Time Required * Machine Rate

= 494 * 30

= £14,820

Material Cost (£/ton) = £800

Material Required = (Weight per Part * Quantity Required) +10% Safety/Wasteage Factor

= 2.45 tons

Masterbatch Colorant Weight Required = 25kg/ton of material

= 75kg (sold in 25kg bags)

Masterbatch Colorant Cost (£/Kg) = £2.50

Total Material Costs (£) = (800 * 2.45) + (2.5 * 75)

= £2,147.5

Total Cost (£) = Cost of Tooling + Cost of Machine Time (including setting) + Cost of Material

= £43,000 + £14,820 + £2,147.5

= £59,967.5

The cost per part is around 12p.

4
Henry Wallace 2016

Materials, Manufacture and Cost

Component 1: Palette Base

Material: Lotte Starex BC-0130X ABS

Material Selection: ABS was chosen for its high surface finish capabilities, low shrinkage while
cooling, and relative strength. A resistance to corrosion was also desirable in this part. The Lotte
Starex BC-0130 grade was chosen as it is a fine injection moulding grade, and has a low cooling time
in mould.

Cost: £800/Ton (based on market price of similar ABS grade on zauba.com market tracking website)

Forming Process: Injection Moulding

Process Selection: Injection moulding is a capable, fast method of producing components of this size
economically. The scale of manufacture is large enough to justify tooling costs.

Component Analysis:

Gate Positions: Shown On Component Drawing

Part Volume (cm3): 4.24

Shot Volume (cm3): 4.24 * No. Of Cavities = 4.24 * 6 = 25.44g

Material Density (g/ cm3): = 1.05

Part Weight: Part Volume (cm3) * Material Density (g/ cm3) = 4.24 * 1.05 = 4.5g per part

Tooling:

Injection System: Gpe 20, with recommended shot weight PS 23g

Split Lines: Shown In Sketch Work

Ejector Points: 3 Pins, one at centre of snap-fit feature, two on inside of main cavity.

Hot Runner System: Milacron Mold-Masters Fusion Series Hot Runner, Star Shaped with Single
Heating Element Running Throughout

No. Of Cavities: 6

Total Clamp Force Area (mm2): 12169

Clamp Force per Cavity (tons): 7.87

Cycle Time (s): 19.3

The screenshot below shows the model developed in order to fine tune the machine parameters.

5
 Henry Wallace

Costings and Machine Calculations Model Screenshot for P01:

6
2016
Henry Wallace 2016

Summary of Mouldability Analysis: A summary of the mouldability analysis continues below, but full
details and images are available in the attached report printout.

Mouldability: The part has no predicted difficulties in filling, as the figure shows.

Air Trap: All air trap shown is largely along the split lines of the mould, and it can be assumed would
vent.

7
Henry Wallace 2016

Sink Marks: There is a very small amount of shrinkage at one corner, but it is less than 0.01mm,
which is within the tolerance of the mould tool.

Cooling Time: The part will be cool enough to eject at 8s, as the surfaces which will be liable to warp
will have cooled.

8
Henry Wallace 2016

Component 3: Palette Top

Material: LG SAN 82TR

Material Selection: SAN was chosen for its high surface finish capabilities, high clarity, low shrinkage
while cooling, and relative strength. A resistance to corrosion was also desirable in this part. The LG
82TR grade was chosen as it is a high quality polymer which gave an appropriate cooling time in
mould.

Cost: £1168/Ton (as of July ’16, from zauba.com market tracking website)

Forming Process: Injection Moulding

Process Selection: Injection moulding is a capable, fast method of producing components of this size
economically. The scale of manufacture is large enough to justify tooling costs. The surface finish
requirements are appropriate to be done in tool.

Component Analysis:

Gate Positions: Shown On Component Drawing

Part Volume (cm3): 3.7

Shot Volume (cm3): 3.7 * No. Of Cavities = 3.7 * 6 = 22.2

Material Density (g/ cm3): = 1.07

Part Weight: Part Volume (cm3) * Material Density (g/ cm3) = 3.7 * 1.07 = 4g per part

Tooling:

Injection System: Gpe 20, with recommended shot weight PS 23g

Split Lines: Shown In Sketch Work

Ejector Points: Two-stage ejection, opening up snap-fit feature for easier bump-off. Three pins, one
central to feature, two either side.

Hot Runner System: Milacron Mold-Masters Fusion Series Hot Runner, Star Shaped with Single
Heating Element Running Throughout

No. Of Cavities: 6

Total Clamp Force Area (mm2): 12084.3

Clamp Force per Cavity (tons): 7.05

Cycle Time (s): 19.9

The screenshot below shows the model developed in order to fine tune the machine parameters.

9
 Henry Wallace

Costings and Machine Calculations Model Screenshot for P02:

10
2016
Henry Wallace 2016

Summary of Moldability Analysis: A summary of the moldability analysis continues below, but full
details and images are available in the attached powerpoint printout.

Moldability: The part has no predicted difficulties in filling, as the figure shows.

Air Trap: All air trap shown is along the split lines of the mold, and it can be assumed would vent.

11
Henry Wallace 2016

Sink Marks: There is a very small amount of shrinkage at the injection gate, and around the snap fit
feature, but it is under 0.01mm, and will be covered by the foil finish, and become acceptable.

Max Cooling Time: The majority of the component will be absolutely cool within 9 seconds,
although there will be warm spots at the base of the snap fit feature.

12
Henry Wallace 2016

Bought-In Components
Pressed Powder Godet

Supplier: DR. FRANKE Umformtechnik

Reason for Buying In: This is the cosmetic powder godet that is inserted into the palette produced
by the cosmetics manufacturer.

Cost: Responsibility of cosmetics company buying this casing.

Costings
Parts Cost

Palette_Base £59,944.04

Palette_Top £80,754.10

Total £140,698.14

Cost per Unit £0.282

Drawings
See Attached Engineering Drawings

D01 – Palette Base

D02 – Palette Top

G01 – General Arrangement

13